Abstract
The present work investigates solid biofuel, derived from household food waste (food residue biofuel, FRB) as a potential bioenergy source in cement manufacturing. Up-to-date investigations of household food waste as a solid fuel focused on composition and heating value, yet no results are available regarding impact on plant efficiency and emissions upon utilization. A multidimensional model based on fundamental principles (mass and enthalpy balances) is used together with actual data from fossil fuel operation to identify and quantitatively asses the impacts on plant performance, product quality and atmospheric emissions. Τhe energy needed to prepare low moisture FRBs is determined and suitable processes are singled out. Key issues of cement plant operation are identified and quantitatively assessed via simulation in an actual dry-process plant, when FRBs substitute 20% of thermal energy (provided by petcoke). The facility utilizes 1.65 × 105 tpa of fossil fuels to produce 1.5 × 106 tpa clinker. It is found that energy efficiency falls and clinker production diminishes by about 0.5 t clinker/t FRB. Refractory thermal rating and main blower capacity constraints remain satisfied. Non-biogenic green-house-gas emissions are reduced by ~60 kg/t clinker. Emitted concentrations slightly increase for several pollutants, mainly nitrogen oxides (NOx) hydrogen chloride (HCl) and metals; they decrease for sulphur dioxide (SO2) and particulates. Maximum emission limits are observed for all regulated pollutants but NOx. Incombustible chlorine and inclusions of alkalis in cement increase by ~9%. To reap the bioenergy benefits and mitigate impacts, blends of FRB (~80%wt) with paper residues (~20%wt) are investigated. Conforming to plant operational constraints and product specifications, the blends ensure production level, environmental compliance and reduced emission rates. The results direct towards customer-tailored FRB blends with lignocellulosic residues, that best suit the design, specific quarry raw materials, operating conditions and individual parameters of the cement plant towards more sustainable cement manufacturing.
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